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Maximizing Lightweighting In Steel Automotive Bodies And Frames With The Steel Tube Air Forming (STAF) Process
Ryuichi Funada, Technical Marketing, STAF Project,
Sumitomo Heavy Industries
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Contents
Company profile Introduction and Concept STAF parts evaluation Lightweight effect Dropping weight test Feature STAF product machines STAF prototype machine Future technology prospects
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Ø HeadOffice
Sumitomo Heavy Industries, Ltd. ThinkPark Tower, 1-1, Osaki 2-chome, Shinagawa-ku, Tokyo 141-6025, Japan Tel. 03-6737-2000 Fax. 03-6866-5104 URL http://www.shi.co.jp
Ø President Shunsuke Betsukawa Ø Founded November 20, 1888 Ø Incorporated November 1, 1934 Ø Capital 30,872 million yen (As of March 31, 2017) Ø Employees Consolidated : 18,491 (As of March 31, 2017) Ø Net sales Consolidated : 700,838 million yen (FY 2017)
1 Company profile
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Business Segments Major Products
1 Company profile
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1 Company profile
50�
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Contents
Company profile Introduction and Concept STAF parts evaluation Lightweight effect Dropping weight test Feature STAF product machines STAF prototype machine Future technology prospects
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2 Introduction and Concept
We propose STAF (Steel Tube Air Forming) process, which is a type of hot metal gas forming.
Feature ・Lighten ; Flanged tube structure.
Continuously varying the closed cross-section. ・Strengthen ; 1,500MPa tensile strength. ・Simplify ; Hot blow forming in one-pack.
Sec-A
Sec-B Sec-C
Sec-A Sec-B Sec-C
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Tube yard preforming
• Form high strength and high rigidity auto parts in one-pack. • Form flanges, drastically the assembly processes are
reduced.
STAF press machine (800Ton)
Piercing & Cut
2 Introduction and Concept
Ⅰ Setting
Ⅱ Heating
Ⅲ 1st blow forming (Projec)ngaflangepor)on)
Ⅳ Forming cross section and die quenching
Forming Process
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2 Introduction and Concept
Hot stamping
Strength
Rigidity
Cold-press
Hydro forming
Spot welding PHS HSS Notes
low strength and need other parts for assembly
low rigidity due to spot welding
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3 STAF parts evaluation test sample parts
Steels Chemical components Carbon equivalent
Ceq HV after
die quenching C Cr Mn Si Ti B
Mn-B 0.21 0.29 1.29 0.16 0.027 0.0018 0.48 440 measured value
Table1 material
Table2 forming conditions
Cross section
270mm
40mm Spot welding
Conditions
STAF
Hot stamping
The nugget diameter 4.5√t( =5.69mm)
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Forced displacement
Complete restraint of the rear side
Rotate the front side Torque 300N・m
Longitudinal bending
Lateral bending
Torsion
3 STAF parts evaluation methods
Forced displacement
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Longitudinal bending
Torsion
3 STAF parts evaluation test results
Stroke(mm)
Forc
e(N
)
23.3 ↑
Stroke(mm)
3.5 ↑ Fo
rce(
N)
0.82°
60.0 ↑
Torq
ue(N
/M)
Torq
ue(N
/M)
14.3 ↑
STAF
Hot-stamping
graph legend
Lateral bending
Twist angle(°) Twist angle(°)
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4 Lightweight effect
• Weight 30% reduction with keeping assembly-rigidity equal • Reduce the number of components and spot welding
Load: 1.0ton
Hot stamp STAF
Thickness 1.8mm/1.5mm 1.2mm(φ58)Weight 4.311kg 2.825kg
Torsional rigidity of Car body
Reducing weight by 1.486kg (About 30%)
STAF Spot welding
Load: 1.0ton
Complete restraint
Hot stamp
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4 Lightweight effect
Alminum extrusion STAF
• Higher strength and Lighter weight than aluminum extrusion • Reduce the production cost by
Aluminum extrusion STAF
Thickness 2.6mm 1.0mmmaterial A6061-T5 MnB5(1.5GPa)Weight 2.407kg 2.164kg
jig
Offset crash analysis
― STAF ― Aluminum
Test result Same conditions
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Height : 6.3m Weight : 500kg Collision speed : 40km/h Collision energy : 31kJ
STAF Hot stamping
5 Dropping weight test
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5 Dropping weight test
• STAF parts ; High energy absorption. • Hot stamping parts ; Broken in two.
STAF Hot stamping
STAF Hot stamping E
nerg
y ab
sorb
ing(
kN)
displacement(mm)
250%↑
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6 Feature
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Hydroforming Hot stamping STAF
Strength 980MPa 1,500MPa 1,500MPa
Parts construction
Cross section image
Process
5 processes 4 processes 2 processes Ø Preforming Ø Hydroforming Ø Laser cutting Ø Press forming Ø Welding(ass’y)
Ø Heating furnace Ø Hot stamping (2 sheets) Ø Laser cutting Ø Welding(ass’y)
Ø STAF (one-pack process) Ø Laser cutting
Pressed parts (2Parts)
STAF part (1 part)
6 Feature
Pressed parts (2Parts)
2 parts 2~3 parts 1 parts
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7 STAF product machines
• The main equipment are STAF press machine and laser cutting machine. • STAF prototype machine has been in operation since September, 2017
Tube yard
800Ton(Hydraulic) STAF servo press
machine
2.5kW STAF laser cutting machine
Power supply/ Control device
Resistance heating device
High-pressure air compressor
21 Confidential STAF-PJ
Trial manufacture of auto parts is available. The conditions of trial manufacture are as fallowing. ・products’ length(~1600mm) ・diameter of a tube(φ50~φ150) ・products’ thickness 1.0mm~2.3mm
8 STAF prototype machine
Prototype forming video
Formable products shape Maximum tube
diameter(φ) 150mm
Minimum tube diameter(φ) 50mm
Full length(mm) 1600
Material length(mm) 7501930
Thickness(mm) t1.0 2.3 Minimum allowable bending radius(R) 500
Minimum allowable bending angle(°)
120°180°
Material Mn-B
22 Confidential STAF-PJ
Records of consideration with OEM
Pedestrian beam Battery frame Door collision beam
Bumper beam Front roof rail side
• Particularly, we’re considering in the development period that’s why it takes a long time for becoming commercial.
23 Confidential STAF-PJ
9 Future technology prospects
Technology Example
Thickness distribution
Tailored tempering
Different diameter
1,500MPa 1,180MPa
1.4t 1.0t
Application to various automotive parts. Tube forming with thickness distribution. Strength distribution by tailored tempering. Tube forming with diameter distribution.
φ50mm φ70mm
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Thank you all for listening
25 Confidential STAF-PJ
FY’13 FY’14 FY’15 FY’16 FY’17~18
Establishing STAF process Product development
Component Technology Prototype machine Commoditizing
Item Ø Material Ø Formability Ø Forming process Ø Complicated shape Ø Proposal for practical use
Shape
Achieved Technology
Ø Hardenability Ø Plunger Sealing Ø High pressure air controlling Ø Tube expanding
Ø Heating Ø Flange forming
Ø Forming process Ø Component design Ø Component evaluation
Ø Press machine design (Laser cutting) Ø Oxidized scale evaluation Ø Weldability evaluation
Ø Quality stability ・Complicated component ・Long curved component Ø Applicability investigation of the Al-Si plating material and Al material Ø Tailored tempering Ø Thickness distribution
APPENDIX
• ~FY’15 Systemizing the forming process and acquiring the basements of know-how • FY’16~ Promotion for the practical application
Sheet material Tube expanding Flanged structure Flange shape control Tailored tempering Thickness distribution